March 2025

This issue of PCD&F / CA brought to you by:

PCB Trace is a subsidiary of Rush PCB Inc.

See us at APEX
Booth #3842

FIRST PERSON
Building a digital pub.
Mike Buetow
MONEY MATTERS
Protect your links on the supply chain.
Peter Bigelow
Reshoring efforts need clear direction.
Greg Papandrew
New business forecasts are always fluid.
Jake Kulp
TECH TALK
Keeping projects on track.
John Burkhert Jr.
PCB design’s AI integration.
Stephen Chavez
Shining a light on cybersecurity.
Alun Morgan
Some live to gum up the works.
Robert Boguski
Driving improvements through internal scoring.
Filemon Sagrero
DEPARTMENTS
March 2025 • VOL. 42 • NO. 3
FEATURES
HIGH-SPEED DESIGN (cover story)
Because flex and rigid-flex PCBs lack ground planes, some designers believe they cannot support high-speed digital signals. But with a mesh or hatched ground plane, it is possible to design systems that include high-speed signals, both single-ended and differential. Some limiting factors for both single-ended and differential signals used in flex PCBs are discussed, as well as simulation data that illustrate bandwidth limits.
by ZACHARIAH PETERSON
PCB Fabrication
Via-in-pad technology permits SMT components to be placed with greater density and helps achieve higher interconnect density. A look at the process from a manufacturing perspective.
by ROY AKBER
INTERCONNECTIONS
Joe Fjelstad, the visionary mind behind the Occam Process – a groundbreaking advancement in solderless electronics manufacturing – shares the journey of Occam and his vision for its transformative potential.
by DAN BEAULIEU
SOLDER JOINT QUALITY
While the initial investment can be costly, implementing nitrogen in the soldering process enhances solder joint quality and manufacturing yields. Whether for reflow, selective or wave soldering, nitrogen can simplify post-soldering cleanup and limit oxidation and contamination.
by MD IMTIAZ UDDIN
ON PCB CHAT (pcbchat.com)
with PRIYANSHA BAGARIA
 
with KENNY MCGEE
 
with ALEX NORMAN
 
with GEOFFREY LEEDS, MATT LEARY AND GEOFFREY HAZELETT

PCEA
PO BOX 807
AMESBURY, MA 01913

PCEA BOARD OF DIRECTORS
Stephen Chavez, CHAIRMAN
Susy Webb, VICE CHAIRMAN
Justin Fleming, SECRETARY
Anaya Vardya, TREASURER

MEMBERS
Jim Barnes
Michael Buetow
Tomas Chester
Douglas Dixon
Juan Frias
Richard Hartley
Matthew Leary
Charlene McCauley
Eriko Yamato

pcea.net

PUBLICATION

WEBSITES

NEWSLETTER

PODCASTS

EVENTS

EDUCATION

AWARDS PROGRAMS

MANAGEMENT
PRESIDENT
Mike Buetow 617-327-4702
mike@pcea.net
VICE PRESIDENT, SALES & MARKETING
Frances Stewart 770-361-7826
frances@pcea.net
PCD&F/CIRCUITS ASSEMBLY EDITORIAL
MANAGING EDITOR
Tyler Hanes 205-258-0067
tyler@pcea.net
COLUMNISTS AND ADVISORS

Jeffrey Beauchamp, Peter Bigelow, Robert Boguski, John Burkhert, Jr., Stephen Chavez, Mark Finstad, Geoffrey Hazelett, Nick Koop, Jake Kulp, Alun Morgan, Susan Mucha, Greg Papandrew, Chrys Shea, Jan Vardaman, Gene Weiner

PRODUCTION
ART DIRECTOR & PRODUCTION
blueprint4MARKETING, Inc.
production@pcea.net
Nathan Hoeller
nathan@pcea.net
SALES
VICE PRESIDENT, SALES & MARKETING
Frances Stewart 770-361-7826
frances@pcea.net
Senior Sales Executive
Will Bruwer 404-313-1539
will@pcea.net
REPRINTS
EVENTS/TRADE SHOWS
EXHIBIT SALES
Frances Stewart 770-361-7826
frances@pcea.net
TECHNICAL CONFERENCE
Mike Buetow 617-327-4702
mike@pcea.net
EVENTS MANAGEMENT
Jacqueline Bress 404-955-7675
jacqueline@pcea.net
SUBSCRIPTIONS

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© 2025, by Printed Circuit Engineering Association, Inc. All rights reserved. Reproduction of material appearing in PRINTED CIRCUIT DESIGN & FAB/CIRCUITS ASSEMBLY is forbidden without written permission.

THE ROUTE
MIKE
BUETOW
PRESIDENT

Wanted: The Irish Pub

It was in 1997 when I visited Ireland for the first time. I was 30 years old then, and had lived in metropolitan cities (Chicago, Providence) for most of my adult life.

Even then, I was fairly well traveled for my age: three continents, 40+ states. And, like many 30-year-olds, I was well acquainted with local nightlife, its various charms and debaucheries, and especially, its demographics.

Through years of travel for business or pleasure, I had come to the realization that most bars (or pubs or haunts or dives or whatever colloquialism you prefer) aimed at a certain clientele. That customer base varied by the place, but in general, there were the bars and clubs for the younger crowd, the pubs for the middle aged, and the lounges for the older set.

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Around the World
news

Icape Group Acquires UK’s Kingfisher PCBs

FONTENAY-AUX-ROSES, FRANCE – Icape Group has expanded its presence in the UK by acquiring Kingfisher PCBs.

The Prestwick-based PCB supplier brings more than 35 years of experience in aerospace, telecommunications, automotive, oil, and gas. The company said its acquisition strengthens Icape’s presence in the UK market and expands its distribution network.

“This latest operation completes the structuring of our Business Unit in the United Kingdom, one of the main European PCB distribution markets,” said Icape CEO Yann Duigou. “Kingfisher’s expertise and established customer relationships complement our existing capabilities and will allow us to provide even better services and support to our customers in the region. We are excited to welcome the Kingfisher team to the Icape family.”

READ FULL ARTICLE

PE Group, FormFactor Team to Acquire FICT

NAGANO, JAPAN – An Asian private equity firm is acquiring printed circuit board (PCB) fabricator FICT Ltd. in a deal valued at 100 billion yen ($656 million).

The deal is expected to close in the current quarter.

MBK Partners and Livermore, CA-based FormFactor Inc. will acquire FICT from Advantage Partners. Under the agreement, MBK will assume an 80% share of FICT, with FormFactor receiving a 20% stake for its $60 million investment.

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Würth Elektronik Finalizes Schopfheim PCB Plant Closure

SCHOPFHEIM, SWITZERLAND – Würth Elektronik closed its PCB production site here in early February after first announcing the move in October. The fabricator will move production from Schopfheim to its three sites in Germany.

“The management and works council have now reached an agreement on a reconciliation of interests and a social plan, which was presented to the affected employees at a works meeting on February 6,” according to the company. “After the closure was announced, companies from the region and neighboring Switzerland contacted us with job offers for the employees in Schopfheim. Würth Elektronik used the contact for an internal job exchange. To date, almost all trainees and around 50 employees have been placed.”

“The production sites in Niedernhall and Rot-am-See will focus on industries and applications whose more complex and individual printed circuit boards are manufactured in Europe for strategic reasons,” said Wurth, which attributes the need to close Schopfheim to “the current worst crisis in the history of the PCB industry in Europe, with a dramatic slump in incoming orders.”

Read Full Article

Vexos Expands Manufacturing Capacity in Vietnam, US

NEW YORK – Vexos in February announced expansions of its Ho Chi Minh City, Vietnam, and Vancouver, WA, facilities to meet increasing customer demand.

The company said these investments will enhance production efficiency, automation, and supply chain flexibility, helping it meet growing customer demand and navigate evolving geopolitical dynamics.

“Our expansion in Ho Chi Minh City and Vancouver, Washington, reflects our commitment to increasing capacity, leveraging advanced technology, and optimizing operations to better serve our customers,” said Paul Jona, CEO, Vexos. “By expanding strategically, we are enhancing agility, reducing lead times, and strengthening supply chain resilience.”

READ FULL ARTICLE

Flex Opens Power Facility in Dallas

DALLAS – Flex has expanded its US manufacturing operations with a new 400,000 sq. ft. facility here, aimed at enhancing its production capabilities for power infrastructure solutions.

The company said the facility will focus on the fabrication and assembly of power pods, power distribution units, and low-voltage switchgear, catering to the growing needs of North American customers.

“Our new Dallas facility positions us to deliver next-generation power infrastructure solutions that help customers maximize computing performance while reducing deployment times,” said Chris Butler, president of Embedded and Critical Power.

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Keytronic Plans $28M Expansion in Arkansas

SPOKANE VALLEY, WA – Keytronic plans to build a $28 million manufacturing facility in Springdale, AR, and anticipates creating more than 400 jobs in the next five years.

The company said it will shift its existing Arkansas operations in Fayetteville to the new 300,000 sq. ft. facility in Springdale in late 2025, which will increase production capacity by approximately 40%.

“We are pleased to announce the expansion of our US manufacturing operations in Northwest Arkansas,” said CEO Brett Larsen. “Our new center of excellence in Springdale will provide both our employees and customers with cutting-edge technology and the increased capacity necessary to accommodate expected growth. We are committed to continuously investing in our capabilities and attracting innovative talent. Our people are our most valuable asset, and we are delighted to enhance our operations in a region where we have maintained a longstanding presence and a strong team and can benefit from a business-friendly environment.”

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AIM Solder Acquires Solder Assembly Materials Firm Canfield Technologies

CRANSTON, RI – AIM Solder has acquired the assets of Canfield Technologies, a fellow producer of solder assembly materials. Financial and other terms were not disclosed.

Canfield’s production operations will be integrated into AIM’s facility in Mexico to optimize manufacturing processes and better serve the company’s global clientele.

In a statement, AIM called the deal a “strategic move aims to enhance AIM’s growth, efficiency, and excellence in the industrial sector. … Their commitment to superior customer service, innovative solutions, competitive pricing, and prompt delivery aligns seamlessly with AIM’s core values.”

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ACT Group Acquires UK-Based Assembler Active-PCB

READING, UK – UK-based electronics manufacturer Active-PCB has announced its acquisition by Agile Circuit Technologies Group.

“Active-PCB was founded 28 years ago by Gary Turner and Marinela Covachã, with a relentless focus on providing highly responsive service to address customer’s underlying needs,” said Active-PCB CEO Mark Aitken. “ACT Group’s culture and strategy is a perfect fit with this founding ethos. We are excited about the prospects for our customers and ourselves in this new partnership.”

Active-PCB provides electronic and mechanical assembly solutions for everything from early design and prototyping to volume production. ACT Group offers PCB manufacturing and assembly services for various industries, including communications, industrial control, consumer electronics, medical, automobile and aerospace.

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Around the World
briefs

PCD&F

AT&S completed the sale of its printed circuit board plant in Ansan, Korea, to Somacis.

Electra Polymers will be the primary supplier of inkjet solder mask for TLT PCB’s new manufacturing facility in Vilnius, Lithuania.

GUH Holdings, a Malaysian PCB fabricator, is transferring its industrial land in Suzhou, China, to the Chinese government for 195 million yuan ($27 million).

Murata Manufacturing is entering India’s Tamil Nadu state with a factory at OneHub Chennai Industrial Park to produce multilayer ceramic capacitors.

Red Board Technology will build a $110 million PCB manufacturing plant in Kim Bang I Industrial Park in Ha Nam, Vietnam.Article ending bug

CA

Altus Group launched in-house x-ray inspection services.

Apple in concert with Foxconn announced plans for a 400,000 sq. ft. factory in Texas to build AI servers.

ASM Technologies announced plans to invest INR510 crore ($5.9 million) to expand its design-led manufacturing and precision engineering capabilities in Karnataka, India.

BayaTronics installed a Seica Pilot V8 NEXT flying probe system at its Concord, NC, facility.

Best Inc. announced the launch of new lead tinning services for electronic components.

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Around the World
PEOPLE

PCD&F

AdvancedPCB announced Tom Caldwell as chief financial officer.

AT&S appointed Dr. Michael Mertin CEO and member of the management board.

Ventec appointed Sunny Kwok technical sales representative for UK and EMEA regions.

Shield AI named Matt Kennedy staff electrical ECAD/PCB engineer.

Summit Interconnect named Michael Trammel senior director of aerospace and defense engineering and Leo LaCroix vice president of A&D operations.

Read Full Article

CA

ATA IMS appointed AV Kamaraj COO.

Federal Electronics appointed Will Oliver vice president of business development.

Heraeus Electronics Toni Versluijs president.

Intervala appointed Robert McKernan president and CEO.

ITM Consulting added Tom Zanatta as principal consultant.

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PCEA current events
national news

AI Implementation TG to Meet in March

PEACHTREE CITY, GA – The AI for Electronics Task Group will meet in March to follow up on the recently published white paper on implementing artificial intelligence in printed circuit design, fabrication and assembly processes.

The task group will discuss present obstacles, such as the potential need for commonly available databases, especially for AOI and SPI, and component sources with available inventory; what education is needed; the status of implementation; and PCEA’s role in promulgating the technology.Article ending bug

PCEA Detroit Technical Conference Registration Open

PEACHTREE CITY, GA – Registration for PCB Detroit, a new technical conference and tabletop event, is now open, PCEA announced in February. The new event takes place June 2-3 on the campus of Wayne State University in Detroit, MI.

The technical program will feature two full days of in-depth electronics engineering training featuring some of the industry’s most esteemed experts. Rick Hartley, Susy Webb, Dan Beeker, Stephen Chavez, Ethan Pierce, Dave Lackey, and Bob Carter are among the headliners of the premiere conference.

The scope of classes ranges from controlling noise, using AI in hardware and PCB design, flex and rigid-flex materials and DfM, HDI via design, and PCB cost drivers, among others. In all, PCB Detroit will offer more than 25 hours of technical sessions for every level (novice to expert).

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PCEA Names 2025-26 Directors, Officers

PEACHTREE CITY, GA – The PCEA membership elected its board of directors for the next two years at its annual meeting in October.

Returning to the board are Jim Barnes, Stephen Chavez, Tomas Chester, Doug Dixon, Justin Fleming, Rick Hartley, Matt Leary, Anaya Vardya, Susy Webb and Eriko Yamato.

New board members include Charlene McCauley and Juan Frias, who was voted in following the meeting as a replacement for the retiring Scott McCurdy.

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Fleming Named First PCEA Training Tech Director

PEACHTREE CITY, GA – PCEA Training in February named respected industry veteran Paul Fleming technical director, PCB design.

Fleming has a long and storied career in printed circuit design, as a designer and with various ECAD companies. He has design experience with various blue-chip OEMs and running a service bureau. He also spent time as a QA engineer and applications engineer with Siemens/Mentor, Cadence and Intergraph. Fleming is a former chapter president of the Designer’s Council and a master instructor in the IPC CID program.

Fleming will oversee the printed circuit board technical programs for PCEA. He will be responsible for coordinating updates to the Certified Printed Circuit Engineering curriculum, including adding targeted modules. He will also be staff liaison to the Conference task group responsible for the technical programs for PCB East, PCB West and PCB Detroit.

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pcea current events

ASSOCIATION NEWS

Designer education classes. The next certified Professional Circuit Designer training and certification class will be held in successive weeks starting May 9. Each class is 40 hours long and includes a copy of Printed Circuit Engineering Professional, a 400-page handbook on circuit board design, and the optional certification exam. The deadline to register for the February class is April 11.

The live, instructor-led classes cover the gamut of printed circuit design engineering, from layout, place and route to specifications and materials to manufacturing methods. Schematic capture, signal integrity and EMI/EMC are also part of the comprehensive program.

There are no prerequisites to enroll. Upcoming classes will be held online. All courses are led by experienced instructors.

Read More

 

CHAPTER NEWS

Greater Michigan. We have interest to start a chapter here. Please contact Mike Buetow at mike@pcea.net for details.

Missouri. The new PCEA Missouri chapter thanks Dale Lee for his presentation on DfA in February. To view the presentation on-demand, visit printedcircuituniversity.com.

Richmond, VA. We have interest to start a chapter here. Please contact Mike Buetow at mike@pcea.net for details.

Read More

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Market Watch

Electronics Industry Demand on Rise

BANNOCKBURN, IL – Orders, capacity utilization and backlogs all increased of late, pushing electronics industry demand higher according to IPC’s February Sentiment of the Global Electronics Manufacturing Supply Chain Report.

The results are based upon the findings of an IPC survey fielded between Jan. 16-31.

The Demand Index is at its highest level since May 2024. Profit margins remain under pressure, but the Profit Margin Index has risen for the second consecutive month. (more)

Read More

Hot Takes

Worldwide semiconductor revenue in 2024 totaled $626 billion, an increase of 18.1% from 2023. (Gartner)

After declining in the first half of 2024, electronics sales bounced back to a 2% annual increase. Sales rose 4% in the fourth quarter and are expected to rise 1% in the current period. (SEMI/TechInsights)

North American EMS shipments fell 2.4% in January compared to the same month last year and dropped 1.8% from December. Bookings slipped 1.2% year-over-year and decreased 15.6% from the previous month. (IPC) (more)

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Booth #1828

roi
Peter
Bigelow

An Ode to Chains

Management decisions threaten the entire electronics industry.

The simple chain is only as strong as its weakest link. Chains have been used for centuries to connect and secure everything from ships to anchors during a storm, large and heavy payloads onto trailers for transport, and more recently, businesses to customers and suppliers for commerce.

Chains are subject to many challenges. Rust and corrosion are the most obvious potential causes of failure for metal chains. Temperature and chemical exposure can cause failure with plastic chains, and politics, as well as epidemics, can test the strength and tenacity of the chains of commerce. And human error challenges each and every one.

Global supply chains have been created, nurtured and evolved into what could best be characterized as one of the most efficient systems ever utilized in the history of manufacturing. The global supply chain that supports our electronics industry in particular has enabled amazingly cost-effective production of high-quality materials, supplies, sub-assemblies and finished products, enabling much higher overall value. The scope of the supply chain is extensive, touching everything from raw materials to consumer products to industrial equipment, and includes not just finished products but also the spare and replacement parts necessary to keep everything functioning long after a product goes into service. This continues to take place despite the pulling, twisting, stressing and testing of each chain’s links over and over again over the past decades.

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Board Buying
Greg
Papandrew

US PCB Manufacturing: 8 Years Later, the Same Challenges – Only Bigger

Naka nailed it: The domestic PCB industry will flounder without a clear direction.

“History is always repeating itself, but each time the price goes up.” – Will Durant

In February 2017, I wrote a column titled “An Afternoon with Naka” in which Hayao Nakahara (or Naka to his friends) – a true PCB veteran embarking on his 60th year in the industry – described the state of the US PCB manufacturing. Naka nailed it then. And eight years and two presidential administrations later, his analysis is just as applicable.

Let’s review some of what I call his “Naka-isms” and how they apply, with the additional element of tariffs, which, for obvious reasons, are top of mind for many in our industry right now.

PCB revenue growth is directly dependent on production capacity. Yes, the purpose of tariffs on imports is to drive business back to domestic shores. But that pesky old law of supply and demand still applies. Because of limited manufacturing capacity in the US (supply), the ever-increasing demand will mean longer lead times and higher pricing. Tariffs increase pricing not only for imports but also for those items made domestically. That’s not just my opinion. It is a historical and economic fact.

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FOCUS ON BUSINESS
Jake
Kulp

EMS New Business Forecasting

Predicting the future is tricky, especially when we don’t yet know the players.

With over 40 years of new business development and marketing experience in the electronics manufacturing marketplace, no sales team requirement produces more dread, apathy or frustration than when we hear, “It is time for your new business forecast for next year.” Contract negotiations, board meetings, airplane travel after 9/11, Covid-induced supply-chain issues, dealing with your cable company and dental appointments; none of these compares to the angst sales leaders experience when forecasting new business from new clients they hope to win and have no current business relationship with.

Is there a less exact science to any required report or activity for salespeople than forecasting clients with whom you have no historical relationship and are competing against other EMS companies to win? Let’s examine some of the truths behind this requirement.

When we consider some of the variables that can affect an accurate, next-year new business forecast, it seems staggering:

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Designer’s Notebook
John
Burkhert, Jr.

Closing the Deal on Concurrent Development

The designer’s (large) role to keep projects on track.

The restaurant industry has a saying, “Time to lean is time to clean.” The gist is that there is never a dull moment while the clock is ticking. Bearing in mind the importance of time, the PCB designer is often faced with the prospect of starting a layout before all the necessary data are on the table. A preliminary schematic and a rough outline are a step in the right direction but by no means the whole story.

That beginning may have been delayed while the schematic capture gets to a state where you have enough information to actually start the physical design segment. In the meantime, it’s always good to inquire about any new connectors or other components to get a jump on obtaining or creating the footprint for the library. These kinds of things are often left to the designer. Going to see the cognizant engineer – or at least chatting them up – will let them know you’re on the job and trying to push forward.

Figure 1. The ECAD station is a pivotal location for creating embedded technology. It may look artistic in the end but a lot of churn is likely to happen before the whole team is on board.
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Booth #3530

design best practices

Stephen Chavez

AI in PCB Design: It’s Already Here

How tools are advancing the speed with which highly computational tasks are performed.

The integration of artificial intelligence (AI) into printed circuit board (PCB) design is no longer a vision for the future; it is a reality. Advanced electronic design automation (EDA) tools now incorporate AI-driven solutions, providing a competitive edge for those ready to embrace this transformative technology. Yet, despite its availability and potential, many remain reluctant to adopt AI.

Given the current shortage and fierce competition for talent, the number of skilled engineers entering the industry is simply not enough, a workforce gap that continues to grow. Companies are addressing this issue as best they can. Current engineers are forced to do more with less, as well as cross-pollinate in disciplines outside their specialty in the quest for project success. New engineers must get up to speed faster, assuming more tasks while learning on the fly, which adds stress and concerns to the project as well as to each individual team member.

Today’s advanced feature-rich EDA tools address these concerns and now include AI-driven solutions to further optimize resources and processes.

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Material Gains
Alun
Morgan

Arms vs. Armor: Security in the Era of Quantum Computing

The infusion of AI into IoT infrastructures shows it’s vital to take cybersecurity seriously.

Although like many of us in this industry, I am fascinated by technology and curious to explore its possibilities, I am no hacker, well-intentioned or otherwise. Yet I do own a couple of gadgets, of course, available through reputable channels, that can sniff for open Internet ports and probe access-control systems, like hotel room keys. It’s got me thinking about the power of tools available to serious-minded hackers who devote their careers and considerable brain power to finding and attacking vulnerable targets online.

In the real, above-board world, we are placing increasing trust in the software applications that enable our lives, infrastructures, jobs and economies. And with the infusion of AI into all these applications, we know less and less about the mechanisms controlling them, or the values directing those mechanisms.

Keeping bad actors out is extremely important, especially as an increasing variety of cyber-physical systems – IoT applications – assist our daily lives at home, on the roads and in factories. As consumers, we enjoy legal protection against many types of cybercrime. We may not know when a connected device like an IP camera has been taken over and used in a botnet. These threats are abstract and virtual.

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HIGH-SPEED DESIGN

Controlled Impedance on High-Speed Flex PCBs

Front-end analysis can help estimate the proper hatch opening – if any – for a flex PCB.
by Zachariah Peterson

Flex PCB and rigid-flex PCB designers are aware of the typical lack of ground planes in a flex design. Due to this and the obvious requirement of ground planes in high-speed PCBs and RF PCBs, one may think that flex PCBs cannot support high-speed digital signals. However, even with a mesh or hatched ground plane, it is possible to design systems that include high-speed signals, both single-ended and differential.

Of course, there are limitations on using hatched ground planes to support high-speed digital signals. For differential interfaces, the hatch has the potential to induce skew, but the superposition of the electromagnetic field from differential signals helps ensure lower noise. In contrast, single-ended signals without a nearby solid reference have the potential for greater radiated emissions from a flex PCB with a hatched ground plane.

Here we discuss some of the limiting factors for both single-ended and differential signals used in flex PCBs and offer some simulation data that illustrates bandwidth limits. Some simple estimators can also be used to determine when a hatched plane is no longer capable of supporting digital signals due to its periodic deviation in input impedance.

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PCB Fabrication

The Via-in-Pad and Wrap Plating Process

How and why to achieve higher-density placement and routing.
by Roy Akber

PCB pin count and interconnect densities are increasing almost daily. Due to the associated high frequencies and speed, not only are impedance matching constraints challenging, but timing is also becoming more important. To add fuel to the fire, the size of the PCBs is getting smaller. Techniques are needed to create space and routing channels on these smaller PCBs. On one end, designers are under considerable pressure to create a design that can meet all the target functionalities. Conversely, PCB manufacturers are facing similar challenges in developing fabrication and assembly processes that can guarantee a reliable product with minimum tolerances.

Via-in-pad is a printed circuit board technology that permits SMT components to be placed with greater density and helps achieve higher interconnect density. In a typical PCB routing technique, escape traces are drawn from the component leads, and then escape vias are used to transition to the next routing layers. These escape traces and their vias require extra space. With via-in-pad technology, the via is inserted on the pad of the component, helping save space and achieve higher-density placement and routing.

This detailed document is intended to demonstrate via-in-pad from a manufacturing perspective.

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Interconnections

Is the Industry Ready for a Solderless World?

The time is now for serial inventor Joe Fjelstad’s answer to simplifying component assembly.
by Dan Beaulieu

Joe Fjelstad is a renowned innovator, environmental advocate and the visionary mind behind the Occam Process, a groundbreaking advancement in electronics manufacturing. In this in-depth conversation, Fjelstad shares the journey of Occam, its transformative potential, and the wisdom gathered over his illustrious career.

Beaulieu: Joe, how did you first conceive the idea for the Occam Process? Was there a specific problem or challenge in the electronics industry that inspired it?

Fjelstad: The idea came on the heels of the lead-free movement which began in the mid to late 1990s. Like many others (and having had environmental leanings since before the first Earth Day in the early 1970s) I was in favor of the lead-free initiative, but some independent digging found it was not necessary based on what I and many others uncovered. Lead in electronics solder represented less than 0.5% of all lead used annually on a global basis.

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Solder Joint Quality

The Benefits of Nitrogen in PCB Soldering

Introducing nitrogen to the solder process can enhance reliability and yields.
by Md Imtiaz Uddin

Inert gas soldering systems, which use a controlled nitrogen blanket atmosphere and an entry vacuum oxygen/nitrogen exchange chamber, offer several key benefits:

  • Oxide formation. Indirectly through its presence, nitrogen minimizes the formation of oxides during soldering.1
  • Flux selection flexibility. Greater flexibility in choosing fluxes.
  • Post-cleaning. Post-soldering cleaning requirements can be reduced or even eliminated.
Figure 1. The presence of nitrogen reduces oxygen in the oven, lessening its impact on solder joints. (Image source: ITW EAE)
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SEEING IS BELIEVING

robert
boguski

One Small Person

Watch out for the one who lives to throw a wrench in the works.

I have this idea. Rather than having the nuclear codes reside in the White House, they should embed with the American people on a rotating basis. Not unlike the Stanley Cup, which overnights in each offseason residence of the members of the NHL championship team. Do the same with the car keys to obliteration; move them from place to place nightly. Think of the possibilities: who will have the effrontery to keep up with the Joneses, especially when they have the power to unleash Armageddon with one push of a button? There goes the neighborhood, indeed. Think twice before criticizing their taste in wainscoting. Consider if the nuclear football kicked off in a house with Polish heritage and a long memory, still seething over the “stolen” Russian win in the gold medal game of the 1972 Olympic basketball tournament. Revenge is a dish best served with beer and hors d’oeuvres, watching live cable, and Poles do not fancy Russians. Talk about checks and balances. What could possibly go wrong with this exercise of grassroots democracy?

Now contemplate the person who makes a career at Underwriters Laboratories. A different kind of soulless annihilation.

Why do people want to work for Underwriters Laboratories? An existential question if ever there were one. What thought process propels UL into focus when mapping one’s career path? Once hired, what launches ULers from their beds each morning, zealous to certify that products won’t explode, impale, eviscerate or otherwise maim the user? What prompts certain individuals keen to become grade school crossing guards of the mind and be content with that role for life? Does the meticulous completion of forms have an aphrodisiacal effect? Absent prodigious financial reward or immense political power, what else moves these people?

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GETTING LEAN

Filemon
Sagrero

How an Internal Scoring System Drives Continuous Improvement

Using Lean Six Sigma to prioritize projects, optimize capex, and inform employee recognition.

Lean Six Sigma is a powerful tool for production teams committed to continuous improvement. Viewed as individual activities, however, the overall impact of the improvements it drives may not be obvious. The Continuous Improvement teams in SigmaTron International’s Tijuana, Mexico, facility address this with an annual review meeting that looks both at accomplishments over the past year and year-over-year trends. The top three teams are recognized for their accomplishments.

A visual dashboard displays key metrics. These include:

  • Kaizens by engineer
  • Area of project impact (quality, efficiency, safety, preventive action or cost)
  • Improvement status
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PCD&F

Hirose DF53 Series Connector

DF53 Series connector is part of the SignalBee connector platform. Features a height of 1.45mm and a depth of 3.55mm, and is said to be the industry’s smallest 0.6mm crimp connector. Supports up to 1.3A max when using two positions for power and is commonly used to bring power to wearable battery connections. Features a unique lance design and combines a miniature footprint with high lance strength to prevent cable disconnect during wiring. Also includes a double lock design, friction and contact, to ensure high retention force. Box-shaped contact design is said to ensure contact stability from above and below, and box-shaped contact on the cable side also prevents deformation when handling the cable assembly. Comes in a 14-position version and permits checking of mating conditions.

Hirose Electric

hirose.com

 

Keystone PCB Edge Connectors

Compact SMT PCB edge connectors feature a horizontal orientation, for parallel board-to-board or board-to-component power or signal transfer. Provide a low-profile connection with a small footprint, supporting high-density, high-current PCB packages on power and aluminum backplanes, and are compatible with PCB soldering applications, including reflow. Are manufactured from phosphor bronze with gold plate and come in various styles: male (pin), cat. #6100 (bulk) or cat. #6100TR (tape and reel) and female (socket) cat. #6102 (bulk) or cat. #6102TR (tape-and-reel). Female sockets are equipped with side guides for additional reinforcement to minimize PCB movement when installed.

Keystone Electronics

keyelco.com

CA

Apollo Seiko EF 3040A Selective Soldering Machine

EF 3040A selective soldering machine combines features such as live teaching, Gerber data teaching, and a 6.5kg solder pot capacity for ultimate flexibility. Features a patented direct drive motor and impeller that minimizes sludge, dross and dust while ensuring easy maintenance, plus advanced options such as auto flux detection sensors, nitrogen purity checks and MES system compatibility for smart factory integration. Also comes in inline model that includes an edge belt conveyor unit for smooth PCB handling and an array of customizable nozzle options. Features remote assistance and diagnostics capabilities to ensure maximum uptime, while advanced teaching methods provide flexibility for various production requirements.

Apollo Seiko

apolloseiko.com

 

Asys SynapticaOS MOM Software

SynapticaOS manufacturing operations management (MOM) integrates MES functions with advanced production and material flow optimization to minimize downtime, enhance efficiency, and deliver real-time monitoring with seamless machine integration through an intuitive interface.

Asys Group

asys-group.com

Technical Abstracts

In Case You Missed It

Defect Detection

“Multidimensional Computed Measurement for Highly Accurate PCBA Defect Detection”

Authors: Zefang Chen, et. al.

Abstract: Accurate defect detection in industrial automated optical inspection (AOI) directly affects product quality and production efficiency. Although numerous techniques have been developed for industrial defect detection, most of them rely on single-texture image data. This dependence limits the accuracy and robustness of the defect detection due to inadequate optical source information. To overcome the problem of low accuracy owing to the lack of 3-D topographic information, a multidimensional information fusion (MIF) module is proposed that fuses texture image and depth image features. The MIF module includes tailored mechanisms to fully extract complementary semantic information from space and channel dimensions. A hierarchical fusion strategy further improves feature integration by enabling higher-layer feature fusion via lower-layer transformer blocks and efficiently removing redundant features. Afterward, feature extraction is performed on the fused feature map, and output is obtained. To enhance the detection accuracy, the position information mask (PIM) module is introduced for post-processing. The PIM module uses surface mount devices (SMDs) position data from Gerber files to create a position information mask. The mask helps filter out defects that are often misidentified owing to missing design information. The results of the comparative experiments demonstrate that the average accuracy of the authors’ method on the printed circuit board assembly (PCBA) defect dataset is 99.93%, which is 5.64% higher than that of conventional YOLOV5. Further, a comprehensive ablation study is conducted to elucidate the contribution of the proposed MIF and PIM modules. It demonstrated that the present model serves as a valuable reference for PCBA surface defect detection. (Optics Express, February 2025, https://doi.org/10.1364/OE.551868)

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